Non-invasive fluid flow detection using digital accelerometers

ABSTRACT

A system for estimating fluid flow in a system including a pump and a fluid vessel operatively coupled to the pump via a conduit is described herein. The system comprises an accelerometer affixed to an exterior surface of the conduit, wherein the accelerometer is configured to generate signals representing physical movement of the conduit, and wherein the signals are suitable for estimating fluid flow in the conduit.

RELATED APPLICATIONS

This application is a continuation application of ContinuationApplication No. 15,793,745, entitled NON-INVASIVE FLUID FLOW DETECTIONUSING DIGITAL ACCELEROMETERS, filed Oct. 25, 2017, which is acontinuation application of application Ser. No. 14/951,068, entitled“NON-INVASIVE FLUID FLOW DETECTION USING DIGITAL ACCELEROMETERS”, filedon Nov. 24, 2015, which claims priority to U.S. Provisional ApplicationNo. 62/083,765, entitled “NON-INVASIVE FLUID FLOW DETECTION USINGDIGITAL ACCELEROMETERS”, filed Nov. 24, 2014, the contents of which isincorporated by reference in their entireties herein.

BACKGROUND OF THE DISCLOSURE Field of the Disclosure

The present disclosure is directed to fluid flow detection. Morespecifically, certain embodiments of the present disclosure relate tothe detection of fluid flowing in conduits, vessels or other physicalmediums, utilizing accelerometers.

Description of the Background

Fluid flow sensing is an important aspect of many industrial, medicaland commercial systems, and is often accomplished using one or more flowsensors. A flow sensor is a device for sensing the rate of fluid flow.Typically a flow sensor is referenced as the sensing element used in aflow meter, or flow logger, to record the flow of fluids. There arevarious kinds of flow sensors and flow meters, including some that havea vane that is pushed by the fluid and that can drive a rotarypotentiometer or similar device. Other flow sensors are based on sensorswhich measure the transfer of heat caused by the moving medium. Thisprinciple is common for microsensors to measure flow.

Flow meters are related to devices called velocimeters that measurevelocity of fluids flowing through them. Another example of flowmeasurement is the laser-based interferometry often used for air flowmeasurement; but for liquids, it is often easier to simply measure theflow. Another approach to flow measurement is Doppler-based methods.Hall effect sensors may also be used, such as on a flapper valve, orvane, to sense the position of the vane as displaced by fluid flow.Other examples of flow sensors include Doppler (ultrasonic) sensors,sensors based on the Coriolis Effect, thermal mass flow sensors, Venturimeters and vortex flow meters, among others.

While such configurations are accurate for sensing fluid flow, they areexpensive and often require invasive sensors that complicate theinstallation process for the sensor itself into the system in which flowis to be measured. What is needed is a non-invasive sensingconfiguration that is inexpensive yet sufficiently accurate to measurefluid flow.

BRIEF DESCRIPTION OF THE FIGURES

The present invention is illustrated by way of example and notlimitation in the figures of the accompanying drawings, in which likereferences indicate similar elements and in which:

FIG. 1 illustrates an exemplary fluid detection system comprising acontainer, pump, accelerometer and processor under one exemplaryembodiment;

FIG. 2 illustrates an exemplary accelerometer suitable for use in theembodiment of FIG. 1;

FIG. 3 is an exemplary signal diagram illustrating the accelerometerdetections of fluid flow of empty tube to full under one embodiment; and

FIG. 4 is an exemplary signal diagram illustrating the accelerometerdetections of fluid flow of full tube to empty under one embodiment.

DETAILED DESCRIPTION

Exemplary embodiments will now be described more fully with reference tothe accompanying drawings.

Exemplary embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that exemplary embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some exemplary embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a”, “an” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on”, “engaged to”,“connected to” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto”, “directly connected to” or “directly coupled to” another element orlayer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another element,component, region, layer or section. Terms such as “first,” “second,”and other numerical terms when used herein do not imply a sequence ororder unless clearly indicated by the context. Thus, a first element,component, region, layer or section discussed below could be termed asecond element, component, region, layer or section without departingfrom the teachings of the exemplary embodiments.

Various embodiments will be described herein below with reference to theaccompanying drawings. In the following description, well-knownfunctions or constructions are not described in detail since they mayobscure the invention in unnecessary detail.

Turning now to FIG. 1, illustrated is a system 100 in which a fluidcontainer 108 containing fluid 109 is fluidly coupled to pump 104 viatube 105. In one exemplary embodiment, pump 104 may be a peristalticpump coupled to container 108 via flexible tubing 105, which may bemanufactured from a suitable rubber, plastic or polymer such aspolyvinyl chloride, silicone rubber, fluoropolymer, PharMed and thelike. In another embodiment, tubing 105 may comprise a rigid orsemi-rigid material. Peristaltic pump 104 may be configured as apositive displacement pump used for pumping a variety of fluids throughoutput tubing 102. The fluid is contained within tube 105, as may befitted inside a circular pump casing (or linear peristaltic pump, as thecase may be). Typically, a rotor with a number of rollers (or “shoes”,“wipers”, or “lobes”) attached to the external circumference of therotor compresses flexible tube 105 to provide fluid flow. As the rotorturns, the part of the tube under compression is pinched closed (or“occludes”) thus forcing the fluid to be pumped and thus move throughthe tube. Additionally, as the tube opens to its natural state after thepassing of the cam (“restitution” or “resilience”), fluid flow isinduced to the pump.

In an embodiment, pump 104 may comprise two or more rollers, or wipers,occluding the tube and thereby trapping between them a body of fluid.The body of fluid is then transported, at ambient pressure, toward thepump outlet 102. Pump 104 may be configured to run continuously, or maybe indexed through partial revolutions to deliver smaller amounts offluid. While a peristaltic pump is disclosed herein, it should beunderstood by those skilled in the art that other types of pumps arecontemplated in the present disclosure, including reciprocating pumps,rotary pumps, and the like.

In the exemplary embodiment of FIG. 1, accelerometer 106 is coupled toan outer portion of tube 105 via fastener 106, which may comprise aclamp, tie, band, all by way of a non-limiting example. In oneembodiment, accelerometer 106 is coupled via communication circuit 112and wire 110 to a processing apparatus 150, such as a controller,microcontroller or computing device, all by way of non-limiting example.Communication circuit may 114 be configured to provide communications inany suitable wired communication protocol, including, but not limitedto, RS-232, SMBus, I2C, USB, IEEE-1394 and the like. In anotherembodiment, communication circuit 114 of accelerometer 106 may beembodied as a wireless communication circuit, which communicativelycouples accelerometer 106, using wireless communication 112, withprocessing apparatus 150 via any suitable wireless protocol including,but not limited to, WiFi, Bluetooth, or any other suitable wirelessprotocol known in the art.

In certain embodiments, the example of FIG. 1 includes a singleaccelerometer assembly, comprising accelerometer 106, communications114, and a mechanism 106 for attaching them to a flow surface. In otherexemplary embodiments, system 100 may include a plurality ofaccelerometer assemblies distributed along the same conduit. Forexample, a second accelerometer assembly 116 may be provided on a secondpoint of a flow surface for tubing 105. Utilizing a plurality ofaccelerometer assemblies may be advantageous in that the secondaryaccelerometer readings may provide useful data for improving theaccuracy of the overall flow sensing, and/or provide additionalaccelerometer data points in which specific flow characteristics may bedetermined. For example, secondary accelerometer readings may be used toconfirm data produced by a first accelerometer and/or confirm flowdirection. As the accelerometer assemblies may be placed a certaindistance apart, the time differences between each reading may be used todetect flow direction and/or other characteristics of the flow in thetubing such as blockage, leaking, bubble detection and obstruction forexample.

In certain exemplary embodiments, system 100 of FIG. 1 may also includeaccelerometer assemblies affixed to the pumping mechanisms themselves.As can be seen from FIG. 1, accelerometer assembly 118 may be affixed topump 104 on a pump casing using any suitable fastening mechanism,including, but not limited to, an adhesive, bonding agent, screw, rivet,nail, or any combinations thereof. Accelerometer assembly 118 may alsobe integrated into pump 104 itself, or also affixed between a pumpcasing and tube 105.

Turning now also to FIG. 2, an exemplary simplified block diagram ofaccelerometer 106 is illustrated. In this example, the accelerometer isembodied as a three-dimensional accelerometer, although it is understoodby those skilled in the art that other types of accelerometers may beutilized. Sensor 204 may be embodied as a capacitive sensor, althoughother components (e.g., piezoelectric, piezoresistive) may be modifiedor substituted for specific applications. The accelerometer may be, forexample, digital, such as to allow for the accelerometer to more readilyinterface with additional digital systems.

In certain embodiments, sensor 204 may comprise a plurality of surfacemicromachined capacitive sensing cells and a signal conditioning ASICpackaged in a single integrated circuit. The sensing cell may beembodied as a mechanical structure formed from semiconductor materials,such as polysilicon, using semiconductor processes (e.g., masking andetching). In certain embodiments, it may be modeled as a set of beamsattached to a movable central mass that moves between fixed beams. Themovable beams can be deflected from their respective rest positions bysubjecting the system to an acceleration.

In certain embodiments, as the beams attached to the central mass insensor 204 move, the distance from them to the fixed beams on one sidewill increase by the same amount that the distance to the fixed beams onthe other side decreases. This change in distance may be used to measureacceleration. The cell beams may be formed as two back-to-backcapacitors for example. Thus, as the center beam moves withacceleration, the distance between the beams changes and eachcapacitor's value will change, i.e., (C=Aε/D), where A is the area ofthe beam, ε is the dielectric constant, and D is the distance betweenthe beams.

In certain embodiments, a capacitance-to-voltage converter 205 mayinclude an ASIC implementing switched capacitor techniques to measureg-cell capacitance and extract acceleration data based upon thedifference between capacitors. The ASIC may also condition and filterthe signals 206 via switched capacitors, providing high level outputvoltages to X, Y and Z-axis modules 210-212 that are ratiometric andproportional to acceleration. Ratiometricity refers to the output offsetvoltage and sensitivity that may scale linearly with applied supplyvoltage. That is, as supply voltage is increased, the sensitivity andoffset increase linearly; and as supply voltage decreases, and offsetand sensitivity decrease linearly. This feature is advantageous wheninterfacing to a microcontroller (150) or an A/D converter because itprovides system level cancellation of supply induced errors in theanalog to digital conversion process. The timing of accelerometer 106may be provided by clock 208, which operates using oscillator 207.Additional accelerometer signal processing may be provided by controllogic/DSP 209 to modify parameters for accelerometer signal readingsincluding, but not limited to, configuring buffers, adjusting motiondetection and transient detection, enhancing orientation, hysteresis,configuring Z-lockout and the like.

Depending on the application, the accelerometer's sensitivity (g-sense)may be adjusted, for example, via logic switches, independent of, or inconjunction with control logic/DSP 209 to allow for a plurality ofsensitivities. Depending on the logic input placed on the pins, theinternal gain may be changed allowing it to function with a plurality ofsensitivities (e.g., 1.5 g, 2 g, 4 g, or 6 g). This feature isadvantageous when applications require different sensitivities foroptimum performance (e.g., applying accelerometer(s) to a fluid bag vs.tubing). The sensitivity may be configured such that it may be changedat any time during the operation.

By affixing accelerometer 106 to tubing 105, based on fluid that ismoved through the tubing by a peristaltic pump (104), vibration pump, orany pump without a steady flow, a signal can be detected proportional tothe pulse of the fluid created by the pumping action. In one embodiment,the Z-axis of the sensor may be arranged against the tubing, with thetubing slightly compressed. Pump 104 may also create vibration along thetube from its operation. Since liquids resist being compressed, theresulting pulse may cause the tube to expand slightly as the pressurewave moves along its length. The expansion should be significantlygreater than any vibration conducted in the tube material alone. Bysensing the motion of the expansion/contraction of the pulse from theaccelerometer, the detection of fluid flow may be realized.

The accelerometer data may be processed to produce a waveformrepresenting the fluid flow, where the difference in the signal betweenthe fluid flowing and no flow or empty tubing is measured and processedby a processing apparatus (150). With reference now to FIG. 3, anexemplary waveform is provided, illustrating an empty tube to full tubeoperation phase (i.e., when fluid is being introduced into the tube). Ascan be seen in the figure, each pulse is shown as a pulse in the tubingfrom the pump action. In stage 302, an exemplary pump is inactive, whereonly ambient noise is measured. In certain embodiments, ambient noisemay be filtered or minimized using accelerometer sensitivity adjustment.In stage 304, the tube is filling during a pump priming process, and theaccelerometer readings increase.

In stage 306, fluid is now flowing and each individual pump is detected.This process continued until stage 308, upon which the pump is stoppedand eventually rendered inactive in stage 310. In certain embodiments,fluid flow may be estimated using processing apparatus 150.Accelerometer pulses may be filtered and/or normalized to induce pulsepeaks to be more uniform, and may be subjected to a pulse count forpulses meeting or exceeding a given threshold. By knowing in advance thevolumetric pumping characteristics of the pump and volumetric capacityof the tubing, a flow rate may be advantageously estimated/calculated.In the case of a peristaltic pump, each detected pulse may represent thedosed amount of fluid between each roller in the pump. In the case of avibration pump, each detected pulse may represent the thrusting actionof the pump. Using this known dose amount may then be used in acalculation to determine the amount of fluid flowing.

Turning to FIG. 4, an exemplary waveform is provided, illustrating afull tube to empty tube operation phase (i.e., when fluid begins toempty from the tube). After being inactive in stage 402, fluid begins toflow in stage 404 and accelerometer pulses may be detected. In stage406, fluid begins to run out and bubbles may form in the tubing,resulting in successively smaller pulse amplitudes. In stage 408, fluidflow is minimal or nonexistent, and the tube is substantially pumpingonly air. In stage 410, the pump is stopped and the system is thusrendered inactive in stage 412.

Similar to the embodiment in FIG. 3, accelerometer pulses may befiltered and/or normalized. However, due to the amplitude minimizationof stage 406, it may be desirable to employ a plurality of thresholds inprocessing the pulses to estimate fluid flow. In one example, fivethresholds may be engaged in processing device 150 to represent 20%reduction in fluid flow. Thus, pulses measured at a full threshold wouldrepresent a 100% fluid flow, and pulses measured at the next thresholdwould represent an 80% fluid flow. Accordingly, the predeterminedvolumetric flow discussed above would be weighted by multiplying thepredetermined value by 80%. The next threshold would represent a 60%fluid flow weight, followed by a 40% fluid flow weight, and so on. Byemploying multiple weights, a more accurate flow reading may beobtained.

Of course, one skilled in the art would understand that any suitablenumber of thresholds may be utilized, depending on the accuracy needs ofthe application. Furthermore, negative thresholds may be used to detectthe positive and negative phases of the accelerometer pulse signal.Moreover, additional signal processing techniques may be used, such aszero-crossing detection, to further increase accuracy.

The skilled artisan may recognize, in light of the discussion herein,that aspects of the instant disclosure may be employed in any systemrequiring fluid flow detection such as, but not limited to, medicalsystems such as those employed in hemodialysis, beverage dispensingfountains, and the like. When so-employed, the disclosed systems may beprovided at lower cost and less invasively and intrusively than knownsystems. For example, proportional detection of fluid flow principallyfrom a position external to the flow conduit negates the need to insertthe detector into the fluid flow, and accordingly decreases theintrusiveness and increases the cost-effectiveness of detection; and theplacement of a detector principally external to the conduit modifies therequirements for the detector's specifications, thus further loweringcosts.

In the foregoing Detailed Description, it can be seen that variousfeatures are grouped together in a single embodiment for the purpose ofstreamlining the disclosure. This method of disclosure is not to beinterpreted as reflecting an intention that the claimed embodimentsrequire more features than are expressly recited in each claim. Rather,as the following claims reflect, inventive subject matter lies in lessthan all features of a single disclosed embodiment. Thus the followingclaims are hereby incorporated into the Detailed Description, with eachclaim standing on its own as a separate embodiment.

What is claimed is:
 1. A system for estimating fluid flow in a systemincluding a pump and a fluid vessel operatively coupled to the pump viaa conduit, comprising: an accelerometer affixed to an exterior surfaceof the conduit, wherein the accelerometer is configured to generatesignals indicative of vibrations imparted to the conduit solely by thepump; and an inferential engine comprising code executed by at least oneprocessor and capable of relationally inferring fluid characteristics ofthe fluid flow in the conduit from the generated signals indicative ofvibrations of the conduit.
 2. The system of claim 1, wherein theprocessing device is configured to one of filter and normalize theaccelerometer signals.
 3. The system of claim 1, wherein the processingdevice is configured to determine if a portion of the signals meets atleast one predetermined threshold.
 4. The system of claim 3, wherein theprocessing device is configured to count pulses in the portion of thesignals meeting the at least one predetermined threshold.